the sheet metal way covers on my mill are shot. I was just going to tack rubber sheets on the x axis to cover the x ballscrew, but I was wondering if anyone had any ideas that were more likely to work than that. I was thinking about using parts of the way covers to do a better job with the rubber sheet.
I have a similar machine and the covers got so they didn't do a great job of protecting from falling chips, etc. I did the same thing with the rubber but put an "outrigger" on the end of each cover. The cover now rolls over a 1 inch wooden dowel so as the table moves, the covers move too. The length that hangs down gives enough weight so that they always stay taut. It's pretty much the same as the "Y" axis roller and rubber sheet so I don't claim the invention.
It took me a couple of tries to get the metal beat back into shape and the little tabs on the bottom to engage the next cover properly. Patience won out and they do add a mechanical layer of protection to the ways which would otherwise be exposed. The fact is that the table runs almost completely over the covers so no room is really saved by not having them installed.
The rollers do, in fact, roll. That makes the rubber sheets move easily. More pictures attached. The factory one is steel with bearings; mine are wooden dowels that have a screw loosely running. Not classy but quick to make.